Table of Contents Command Series General 6$( 2LO $ERYH Û) Û& .............................................................................................................................5 Command Twin '6$, &RQYHUVLRQ .LW 5HPLQGHU ............................................................................................................................5 '6$, :LULQJ +DUQHVV 8SJUDGH .................................................................................................................
Command Series LDW 702-1404/KDW702-1404 (cont.) Control Panel Indicator Lights.............................................................................................................................25 Key/Key Switch Change .....................................................................................................................................26 New Product Kohler Introduces New Command PRO Horizontal Engine Line........................................................................
Command Series Technician’s Service Test Gasoline ............................................................................................................................................................. 92-95 Diesel........................................................................................................................................................................96 Tear-Out Answer Sheet ..................................................................................................
Command Series Section 1 - Command Series General SAE-30 Oil Above 50°F (10°C) It has been standard practice and was recommended forever to use 10W-30 oil in all Command hydraulic lifter DSSOLFDWLRQV 7HVWLQJ KDV UHFHQWO\ VKRZQ EHQH¿WV VXFK DV improved emissions and reduced oil consumption when SAE-30 oil is used in warm weather.
Command Series DSAI Wiring Harness Upgrade To combat occasional voltage spikes, we have upgraded the wiring harness for both the vertical and horizontal engines. Diode Upgrade Spade Bullet Illustration of Terminal Ends 7KHVH VSLNHV KDYH EHHQ UDQGRP XQLGHQWL¿HG DQG FRXOG occur for a variety of different reasons, but ultimately destroy the DSAI. The upgrade adds diodes to the harness to protect the DSAI up to 3000 watts.
Command Series Incorrect Solenoid Jet (24 757 22-S) 7KH VROHQRLG NLW 3DUW 1R 6 KDV EHHQ LGHQWL¿HG as having been built with the No. 120 jet instead of a SOXJ :KHQ XVLQJ WKLV NLW LW XVXDOO\ UHTXLUHV WKDW WKH SOXJ be removed, and the jet from the original solenoid be transferred to the new solenoid. (QJLQHV WKDW XVH WKLV VROHQRLG UHTXLUH D MHW IURP ± therefore use of the 120 jet will affect the performance of the engine.
Command Series Head Gasket Failures on CH/CV730 (SB-289) (DUO\ SURGXFWLRQ &+ &9 HQJLQHV XVHG D À\ZKHHO FXW IRU %7'& LJQLWLRQ WLPLQJ +HDG JDVNHW IDLOXUHV KDG EHHQ reported due to excessive combustion pressure.
Command Series EFI New EFI Fuel Pumps (24 393 52-S) Starting in March 2008, all EFI engines have been built with fuel pumps from a new supplier. Testing has proven the new SXPS LV PRUH UREXVW LQ ERWK DLU DQG OLTXLG FRROHG HQJLQHV The new pump is similar in size and design and will interchange as Part No. 24 393 20-S supersedes to Part No. 24 393 52-S. Command Single Old vs.
Command Series 10
Aegis Section 2 - Aegis Series LH775-0016 Sputtering :H KDYH UHFHLYHG RFFDVLRQDO UHSRUWV FRQFHUQLQJ VRPH /+ HQJLQHV UXQQLQJ URXJK VSXWWHULQJ DQG VWDOOLQJ LQWHUPLWWHQWO\ ,QYHVWLJDWLRQ KDV UHYHDOHG WKH SRVVLELOLW\ RI D SRRU RU ORRVH FRQQHFWLRQ DW WKH HQJLQH (), UHOD\ .
Aegis Cub Cadet Harness Protection and Vapor Lock &XE &DGHW KDV GHYHORSHG 6HUYLFH .
Courage Series Section 3 - Courage Series General Courage Ring Gear Failures (SB-285) In May 2006 Kohler began using powdered metal ring gears on some Courage engines. Due to reported failures in the ¿HOG DOO &RXUDJH HQJLQHV DUH QRZ EXLOW ZLWK VWHHO ULQJ JHDUV since early March 2008. The symptom of a failed ring gear will be a noisy starter that doesn’t seem to engage or turn the engine over.
Courage Series Courage Single Loose Cover Plate Reminder Steps have been taken to prevent the future occurrence of loose cover plate bolts. The dates for these guidelines took place at Serial No. 36285XXXX3.
Courage Series New Cam Design The new design cam reduces the number of parts in the engine as the gear, lobe, and shaft will be assembled as one part. The assembled cam will provide quality control and consistency in production on the Courage engine equal to the Command Series engines. The design will implement powdered metal lobes that are precision controlled with an LQWHUIHUHQFH ¿W 7KLV FKDQJH LV D UHWUR¿W XQOLNH WKH FKDQJH WR the cam on the Courage Twin.
Courage Series Less reciprocating mass means less force to balance within the system. That means lower bearing loads and longer engine life. To accomplish this, the piston was completely redesigned to UHGXFH PDVV $GYDQWDJHV LQFOXGH Old Style • • • • Wider skirt for better heat transfer from the crown 3LQ KHLJKW LV UDLVHG PP WR UHGXFH ZHLJKW Skirt is 2 mm longer for a better guide in the bore Reduced pin diameter from 22 mm to 20 mm New Style Old vs.
Courage Series 7KH FUDQNVKDIW KDV DOVR EHHQ PRGL¿HG WR LQFUHDVH WKH HFFHQWULF offset by 1 mm. That means the weight will now move a full 18 mm to compensate for the lighter moving parts. $OWKRXJK WKH HQJLQH ORRNV WKH VDPH RQ WKH RXWVLGH WKH EDODQFH system resulted in many changes on the inside. Engine specs will change to make servicing the engine as easy as possible.
Courage Series Courage XT XT Fuel Tank Debris We have found some evidence of debris showing up in the IXHO WDQNV RQ WKH ;7 HQJLQH $ WKRURXJK LQYHVWLJDWLRQ RI WKH FDXVH KDV UHVXOWHG LQ WKHVH ¿QGLQJV Probe Tank Outlet Ignition Ground Concern It is possible that the ignition grounding system on the À\ZKHHO EUDNH PD\ UHPDLQ open, even though the brake bail has been released.
Kohler Diesel Section 4 - Kohler Diesel General Kohler Diesel Service and Support On May 9, 2007 the Kohler Co. announced that it had entered into an agreement to purchase Lombardini Srl. This acquisition was designed to provide the Kohler Co. with a strong complement to our existing Engine Business. Our goal was, and continues to be, to establish a single worldwide distribution network for the sales and service of gasoline and diesel engines.
Kohler Diesel All Air-Cooled Series Outlet to Fuel Lift Pump Inlet Quick Stop Device (QSD) The quick stop device system, or QSD, is available on all multi-cylinder air-cooled series engines. The system uses an electric solenoid in conjunction with the fuel lift pump and check valves to quickly shut down the engine. Use of an auxiliary fuel pump before the QSD is not recommended.
Kohler Diesel 15LD 315-440/KD315-440 Injection Pump Check Valve :H KDYH KDG VRPH UHSRUWV IURP WKH ¿HOG RI SUREOHPV ZLWK these engines not shutting down properly. If checks of the fuel shut-off valve (if supplied) are found to be OK, then the injection pump check valve should be checked. The check valve may be stuck in the open position, allowing fuel from the fuel return line to be ingested and burned. To check this, turn the engine key to the OFF position (if equipped).
Kohler Diesel All Liquid-Cooled Series Fuel Supply Line to Fuel Rail Fuel Return Line From Fuel Rail Fuel Return Line to Fuel Tank Fuel Solenoid Valve Fuel Supply Line From Fuel Lift Pump Banjo Bolt w/Internal Check Valve New Style Fuel Filter Head Part Number ED9820-119-S 13 mm Hex Part Number ED9820-220-S E14 Torx )XHO )LOWHU +HDG 0RGL¿FDWLRQ Beginning at engine Serial Number 5002295 WKH IXHO ¿OWHU KHDG RQ WKH DERYH PHQWLRQHG HQJLQHV KDV EHHQ PRGL¿HG 7KH QHZ ¿OWHU KHDG GHVLJQ SURYLGHV EHWWHU
Kohler Diesel LDW 702-1404/KDW702-1404 )XHO /LIW 3XPS &DPVKDIW /REH 0RGL¿FDWLRQ Starting with the following engine serial numbers: /': .': /': .': /': .': 7KH IXHO OLIW SXPS FDPVKDIW OREH KDV EHHQ PRGL¿HG WR improve fuel lift pump drive rod and camshaft lobe wear, while also allowing easier parts replacement.
Kohler Diesel Oil Pan Removal Please note that when removing the oil pan on these engines, care must be taken not to pull the lateral oil seals, located between the crankcase, front, and rear bearing support, out of their seat. The factory uses a silicone gasket material to seal the oil pan to the crankcase; this sealant may stick to the oil seals.
Kohler Diesel Control Panel Indicator Lights 7KH FRQWURO SDQHO RQ WKH /': .': VHULHV RI HQJLQHV KDV D VHOI FRQWDLQHG HQJLQH VDIHW\ shutdown system as well as several warning indicators.
Kohler Diesel Key/Key Switch Change Starting at engine Serial Number 5252706, the engine key/key switch has been changed to a new style that incorporates a sliding cover. This prevents debris from contaminating the key switch body when the key is removed. The key switch body also has leak holes for drainage. New Style Key/Key Switch The new key/key switches are supplied on all liquid-cooled engines after the above serial number, as a spare part separately, as well as installed in Control Panel Part No.
New Product Section 5 - New Product Kohler Introduces New Command Pro Horizontal Engine Line Kohler Engines is pleased to introduce a new line of product that exceeds the current offering of any other manufacturer in the industry.
New Product +HDY\ 'XW\ $LU ¿OWHU A heavy duty patented air cleaner is standard. It has an indexable cover that allows it to be rotated to capture ZDUP DLU IURP WKH PXIÀHU DQG KHDW WKH FDUEXUHWRU DLU RQ applications that operate in both warm and cold weather conditions. Heavy-Duty Air Cleaner :DUP :HDWKHU YV $QWL ,FLQJ &RQ¿JXUDWLRQ Dual Ball Bearings The Command Pro has ball bearings on both ends of the crankshaft and a cast iron liner for a truly heavy duty, long life, commercial grade engine.
New Product Other Features Along with all of the other standard features, the Command Pro includes electronic ignition, Oil SentryTM ORZ RLO SURWHFWLRQ GXDO RLO ¿OO DQG GUDLQ ORFDWLRQV KHOLFDO FXW JHDUV DQG D \HDU ZDUUDQW\ for commercial users.
New Product Kohler Enters Consumer Horizontal Market The leader in commercial engine products is now manufacturing a line of horizontal consumer engines that has some of the same features as it commercial line. The Slant cylinder overhead valve design engine line has a cast iron liner, dual ball bearings, water trap carburetor, and larger fuel tank (than competitive engines) which includes a serviceable debris screen, and it is all covered by a two year warranty.
New Product Water Trap Carburetor The water trap carburetor controls the moisture that can sometimes create a problem for getting these engines started when used on applications that sit for extended periods or when the fuels attract moisture. Water Trap Carburetor Large Metal Tank and Serviceable Fuel Screen The tank is larger then any other offering from any manufacture in the consumer market. This increases the runtime. The tank screen is removable and allows for ease of service.
New Product New Commercial EFI Introducing the all new self-contained EFI system from Kohler Engines. This “Closed Loop” “Sequential Fuel Injection” system has all the advantages of the current system and more. The self contained system means that all the previously added components are now mounted to the engine and include: • Fuel Pump • Fuel Pressure Regulator • Electronic Control Unit This makes mounting the engine as simple as any carburetor system without the need for a fuel return line.
New Product Courage XT-6 September 2007 marked a great milestone for Kohler (QJLQHV ZLWK WKH ODXQFK RI RXU ¿UVW HYHU HQJLQH IRU WKH consumer walk behind mower market. Although the market has been slow, there are strong indications that sales will grow dramatically in this market as well as in the pressure washer and generator markets over the next few years.
New Product 34
Miscellaneous Section 6 - Miscellaneous Replace Mating Gears It is recommended in situations where a broken crankshaft gear is replaced as a repair that the camshaft should also be replaced. The mating gear will develop a wear pattern, and failure to change it may cause a repeat failure. This suggestion was submitted by a wily old distributor that has experienced this phenomenon many times over his long career. Refer to Service Bulletin 250 for further information.
Miscellaneous Hours 1 8 100 200 500 2,000 3,000 Miles vs. RPM 1800 40 320 4,000 8,000 20,000 80,000 120,000 3600 80 640 8,000 16,000 40,000 160,000 240,000 Miles Traveled vs. RPM Makes You Think... This information came from a service bulletin written by an OEM in the mid ‘70’s. Although there are many factors that play into the life expectancy of an engine, such as maintenance and care, the time factors and comparisons made in the bulletin make you think.
Miscellaneous Who Left the Oil Lights On 7KH 2LO 3UHVVXUH 6ZLWFK 3DUW 1R 6 ZDV ¿UVW introduced into production in January of 2008. We have been receiving scattered reports about the oil light turning on and not shutting off. Service Bulletin 290 outlines details about the two manufacturers that build the switch and how to identify which one is failing. The switches in question all have the date code 806.
Miscellaneous Bearing Failures Bearing failures can be easy to identify but extremely GLI¿FXOW WR WURXEOHVKRRW 2QH FDXVH RI ORZHU EHDULQJ IDLOXUH can be the result of electrolysis. No, it does not involve hair removal. Pre-Emptive Action It is stray voltage attempting to seek an area to ground itself. In this case that area happens to be through the EHDULQJ ,W XVHV WKH RLO ¿OP WR DUF DFURVV WKH JDS LQ WKH bearing causing pitting, scoring, and eventually failing the main bearing.
Miscellaneous Anti-Icing Components For applications that are used in warm as well as cold weather environments, we have some kits available to keep your engine compliant with CARB and EPA regulations while operating in cold weather. Because of the closed breather system required by these regulations, some engines can develop icing when the temperatures reach the freezing point. Icing can affect the performance of the engine and in some instances cause it to run rich.
Miscellaneous Replacement Engine Reminder This is a reminder when replacing an engine you must check to see if the original engine is emission compliant. When re-powering a piece if equipment, it is required by U.S. law that a compliant engine be used if the original engine was EPA or CARB compliant. The information regarding whether an engine is compliant or not can be found on the engine information tag located on the engine.
Miscellaneous Troubleshooting Electric Starters In the years of warranty claims that have crossed our path, one of the items that stands out in our system LV WKH QXPEHU RI ZDUUDQW\ FODLPV ¿OHG RQ HOHFWULF VWDUWHUV WKDW DFWXDOO\ WHVW JRRG For that reason we have added two simple test procedures this year, one for the inertia starter and one for WKH VROHQRLG VKLIW VWDUWHU 7KLV ZLOO KRSHIXOO\ KHOS SUHYHQW ¿OLQJ D FODLP RQ D JRRG VWDUWHU 7KH FRSLHV LQ WKLV book are printed black and white, however full col
Starter Testing Procedures 0.00 VDC 1.00 VDC Questionable (Test 3) VDC 2.00 VDC + 3.00 VDC Not Acceptable (Voltage Drop in electrical path) VDC = Note: Touch meter lead to actual battery terminal. VDC Note: Use starter end plate as + Battery - - VDC test point. + - DVOM - - + test point. - Starter + + DVOM - + VDC Battery - - + - VDC If the value for step 5 or 6 is greater than 50% of the difference in step 4 continue to Step 7. Otherwise the test is complete.
0.00 VDC 1.00 VDC Questionable (Test 3) VDC 2.00 VDC + 3.00 VDC Not Acceptable (Voltage Drop in electrical path) VDC = VDC + Battery - - VDC Note: Use starter end plate as test point. + - Sol. - Starter + - test point. Note: Use starter end plate as Starter + Sol. DVOM - Battery VDC + - + - DVOM - VDC If the value for step 5 or 6 is greater than 50% of the difference in step 4 continue to Step 7. Otherwise the test is complete.
Miscellaneous Kohler PLUS News Carburetor Repair Kits in Kohler PLUS Kohler PLUS has been improved to list the individual carburetor repair kits at the part level of the service carburetor. You can: 1. Search by the XX 853 XX-S part number and bring up the search part information record to see the repair kits, or; 2. Click on the fuel system of a spec. Then click the notepad on the far right of the XX 853 XX-S carburetor kit part number.
Miscellaneous Searchable Literature Descriptions Some recent changes to Kohler PLUS formatting include the ability to now search for a document E\ GHVFULSWLRQ LQVWHDG RI MXVW WKH GRFXPHQW SDUW QXPEHU :KHQ VHDUFKLQJ IRU D GRFXPHQW MXVW W\SH D QXPEHU NH\ ZRUG RU SKUDVH LQWR WKH VHDUFK ER[ IRU that section and click “Go” or hit the “Enter” key. .RKOHU 3/86 ZLOO VRUW WKH ¿OHV DQG UHWXUQ D OLVWLQJ RI RQO\ WKH GRFXPHQWV WKDW FRQWDLQ \RXU VHDUFK criteria.
Miscellaneous Other Enhancements Now Available RPM Idle and High Speed Settings - ORFDWHG LQ WKH VSHFL¿FDWLRQ KHDGHU Fast Moving Parts - found immediately below the engine group listings. Click Here to View Image Click Here to View Literature Relating to the Spec No. News Flash on Kohler PLUS We are now posting all new released literature into one location initially on .RKOHU 3/86
Miscellaneous Expanding the limits of power.
Miscellaneous Date of Application Kohler I.D. No. E-mail Company Name Company Address Business Telephone Number ( City ) Fax Number ( - Name of Applicant Zip ) - Home Address City State Years of Industry Experience (Minimum 1 Year) State Telephone No.( Zip Expert Dealer A check, money order, or credit card must be received with the application to reserve a place in the class.
Warranty News Section 7 - Warranty News Warranty System NOW AVAILABLE The Kohler Engine Division is pleased to announce the start of a new era. Our new Web-Based Warranty Processing System is now available. This Web-Based Warranty System will provide users the capability to submit their own warranty claims, track progress of a warranty claim, and view their own dealership claim history.
Warranty News After entering the system you will see the Warranty Home Page. Warranty Home Page Trusted Site Direction If you encounter a problem while entering a warranty FODLP DOZD\V FKHFN WKDW \RXU FRPSXWHU LGHQWL¿HV WKH Warranty System as a “Trusted Site.” Use the following step-by-step instructions to verify and change settings if necessary. 1. Open Internet Options from Internet Explorer by clicking on Tools > Internet Options. Click “Tools” Menu 2. Click the Security tab. 3.
Warranty News 5. Type the warranty site web address and press the Add button. 6. If the check box by by 5HTXLUH VHUYHU YHUL¿FDWLRQ (https:) for all sites in this zone is selected, remove the check mark. 7. Click the Close button. Enter Warranty as a Trusted Site 8. Click the Custom Level... button; the Security setting window will open. Changing Custom Level 9. From the Internet Explorer Menu, click Tools > Internet Options, then click the Security tab. 10. Change Reset to: to “Medium-Low.” 11.
Warranty News Helpful System Tips • To use the system, all users must obtain a User Account to gain access. Contact your local CD or call the User Account Hot Line at 1-866-255-9220. • Before using our new warranty system, please verify WKDW \RXU FRPSXWHU LGHQWL¿HV WKH ZDUUDQW\ V\VWHP 85/ address as a trusted site. • The user name and password for Kohler PLUS and the new warranty system are typically not the same or shared.
Warranty News EWR Review (Engine Warranty Return) ,I \RX KDYH HYHU GHDOW ZLWK D GLI¿FXOW ZDUUDQW\ VLWXDWLRQ \RX may occasionally have asked yourself how you resolve the problem and who you should go to for help. The following steps outline the procedure required to speed up the painful process.
Warranty News EWR Caution Engines or components returned to Kohler without prior authorization and a visible EWR number have an extremely high risk of being lost or destroyed. It is the Dealer and Kohler Representative’s responsibility WR ¿UVW PDNH D YDOLG HIIRUW WR determine the cause of failure before requesting an EWR and analysis by Kohler Engines. Engines or components returned without requested information may result in time delays as well as non-payment.
Bulletins, Etc. Section 8 - Bulletins, Etc. Beginning this year, we will include every Bulletin, Technical Flash, and TechTip released throughout the past year in this section. This allows you an easier, one stop reference point. In addition to the Update Book, these documents will always be posted on Kohler PLUS under “Associated Documents.
Bulletins, Etc. NO. Parts Bulletin 251 MODEL Walker CH26 DATE ISSUED 7/07 DATE REVISED 1/08 New EFI Long Block for Walker CH26 A new CH26 EFI long block, part number 24 523 01, is now available for servicing Walker CH26 model engines. This long block consists of an assembled crankcase/closure plate (including all internal components) ȱȱ¢ȱǰȱȱǰȱǰȱȱȱĴȱ¢Ȧȱȱ¢ȱ installed.
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Bulletins, Etc. NO. Service Bulletin 285 MODEL SV470-SV620 SV710-SV840 DATE ISSUED 3/07 DATE REVISED 3/08 Loose/Cracked Flywheel Ring Gears ȱȱ¢ȱȱȱ ȱȱȱ ȱȱȱĚ¢ ȱ beginning in 2006. Due to isolated cases of failure, we have made a change from powdered metal ring gears to steel ring gears.
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Bulletins, Etc. NO. Service Bulletin 288 MODEL CH/CV940-980 DATE ISSUED DATE REVISED 12/07 6/94 Flywheel and Mounting Stud Replacement ȱȱęȱǰȱȱȱ¢ȱȱȱȱ¢ȱ Ȧ şŚŖȬşŞŖȱȱȱǯȱ ȱȱ Ě¢ ȱȱȱȱȱȱȱȱȱȱǯȱ ȱȱȱȱȱ ǯȱ WARNING: Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death.
Bulletins, Etc. 6. Remove the screws, reinforcing washers, grass ǰȱȱěǯȱ ȱ ȱŚǯ Figure 6. Removing Flywheel Fastener With Holding Tool. Figure 4. Removing Grass Screen Fasteners. ŗŖǯ ȱȱ¡ȱĚȱ ȱȱ ǯ 7. ȱȱ¢ȱȱȱǯȱ ȱ ȱŗśǯ ŗŗǯ ȱȱȱȱȱȱĚ¢ ȱȱȱ Ğǯȱ ȱ ȱŝǯȱ ȱȱ¢ȱȱ ȱĚ¢ ǯ 8.
Bulletins, Etc. ŗǯ ȱȱ¢ȱ ȱĚ¢ ȱȱȱĞȱ ǯȱ ȱ ȱŞȱȱşǯ Kill Lead Clamp Figure 8. Clean and Dry Flywheel Hub. Figure 11. Ignition Module Mounting Details. 7. ȱȱȱȱȱȱ ¢ȱȱȱ Ě¢ ȱȱȱȱȱȱ ȱȱ ȱȱȱȱǯ Şǯ ȱȱĚ¢ ȱȱȱȱȱ¢ȱ ȱȱȱǯ Figure 9. Clean and Dry Crankshaft Taper. 2. 3.
Bulletins, Etc. 13. Place the leads under the molded clip on the starter side. See Figure 13. 16. Molded Clip ȱȱěȱ ȱ¢ȱȱȱȱ screen onto the four hex studs.
Bulletins, Etc. NO. Service Bulletin 289 MODEL CH/CV730 DATE ISSUED DATE REVISED 1/08 4/08 Flywheel Timing Change CH/CV730 engines ¢ had 22° BTDC ignition timing. With that timing, reports of some head gasket received Ğ the engines got into the ęǰ so the timing then retarded to 16° BTDC. An ě Ě¢ ¢ (Part No. 24 340 02-S) has been created, so engines 22° timing can be ¢ converted to the preferred 16° timing.
Bulletins, Etc. 1. Remove the straight See Figure 3. ě key and discard it. 2. Install the 6° ě key. See Figure 4. Correct orientation of the key is necessary for proper ignition timing. The ę mark must face out, when viewing the Ě¢ as it is mounted. See Figures 5 and 6. ,GHQWL¿FDWLRQ Mark Crankshaft NOTE: Improper installation of the ě key can cause improper ignition timing and damage to the engine. Offset Key Flywheel Figure 6. Correct Offset Key Orientation.
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Bulletins, Etc. HTC-102007 Ground Relocation on Dixon ZTR Mowers Subject: Electrical Grounding on Kodiak 908 and RAM 50 Series Mowers with Kohler CV20 Engines Ground Leads On Silver Closure Plate Screw ȱ ȱ ȱȱ¢ȱȱȱȱȱ ground path and guard against a potential engine failure. 1. ȱȱȱȱȱȱȱǻȬǼȱĴ¢ȱ ȱȱĴ¢ǯ 2.
Bulletins, Etc.
Bulletins, Etc. KEK-032008 XT-7 Fuel Tank Outlet Flash Removal ȱ¢ȱȱ Ȭŝȱ ȱȱȱ ǰȱǰȱȱęȱ¢ȱȱȱ¢ȱȱȱȱǯȱ ȱȱ ȱȱȱĚȱȱȱȱȱǯ WARNING: Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death.
Bulletins, Etc. ARIENS-052008 Courage XT-7 Flywheel Brake Ignition Grounding Issue On some Courage XT-7 engines it is possible that the ignition grounding system on the Ě¢ brake may remain "open," even though the brake bail has been released. In the event that an engine is not grounding or Ĵ down, use the following steps to diagnose and correct the problem. WARNING: Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death.
Bulletins, Etc. TechTip 2008-02 Electronic Governor Overview, Diagnosing, and Troubleshooting (Units with Governor Control Unit 24 584 59-S) There have been some reports regarding the function, adjustment, and troubleshooting of the electronic governor system. ȱȱȱȱȱȱȱȱęȱȱȱȱȱ¢. This document has been made to explain the system, aid in diagnosing and troubleshooting the system and its components.
Bulletins, Etc. ȱȱȱĞȱȱ¡ȱȱȱȱ the actuator reinstall as follows: 1. Disconnect linkage and remove the Digital Linear Actuator (DLA) from the control assembly. See Figure 1. 2. ȱȱĞȱ¢ȱȱȱ ǯȱ ȱ ȱśǯ 3. ȱȱȱȱȱȱ ȱȱǯ Governor Control Unit 4.
Bulletins, Etc. Harness/GCU Trouble Shooting and Diagnostic Procedures Ground and Power Tests The following two tests check for power and ground supply to the GCU. If either test fails the harness, electrical connections, or electrical system needs repair. 1. ȱȱ¢ȱȱȱěȱǯ 2. Remove the GCU and unplug the wiring harness. See Figures 6 and 7. NOTE: It is important to use the proper sized probes to preform the following test.
Bulletins, Etc. OHMs Tests Speed Control Input Remove the GCU and unplug the wiring harness. See Figure 6 and 7. The connection is either a single wire red w/yellow tracer, or a 6 pin connector body with a red wire w/yellow tracer. See Figures 12 or 13. The following two tests are for measuring the resistance of the DLA circuit that send a signal to the GCU. If either test fails the DLA is no good and should be replaced. If both test are good the DLA is neither shorted or open, it is good.
Bulletins, Etc. Governor Control Unit (24 584 59-S) Blink Codes for Software Version: KGETO301 Stored Codes - Activated when the key is turned to the "on" position. LED Diagnostics Failure Condition Possible Causes Response RFI interference Ground to kill, close carb throttle plate Response Time Speed Error Watchdog Interrupt Overspeed (Over 4500 RPM for 0.
Bulletins, Etc. Kohler Electronic Governor Troubleshooting Chart Turn off key switch Do Not Touch the Digital Linear Actuator (DLA) NOTE: The DLA is not a solenoid. It is a precision electronic motor. Do not exert force to the center clevis shaft! Visually inspect the DLA and Linkage. Figure 1 or 4 Fail if Pass if &RQ¿UP WKH IROORZLQJ 1. Clevis shaft and boot in place 2. Clip attached 3.
Bulletins, Etc. Kohler Electronic Governor Troubleshooting Chart (continued) 12 Volt “Power Test” Locate the Speed Control input wire. The connection is either a single wire red w/yellow tracer, or a 6 pin connector body with a red wire w/yellow tracer. See Figures 12 or 13. Unplug and connect a jumper wire to the red wire with a yellow tracer on the engine wire harness. or Probe red w/yellow wire on 6 pin connector. Start the engine in the normal manner as described in the Owner’s Manual.
Bulletins, Etc. B+ Kill Tab (speed signal) 10 Power 8 12 Speed Signal 14 Device Ground Ignition Module DLA Driver Controls 13 1 2 6 7 2B 2A 1A 1B Application Supplied Speed Control Input DLA Operation Input Voltage: 0 Volts at Idle/12 Volts at High Speed Figure 17. Basic Electrical Diagram of System.
Bulletins, Etc. TechTip 2008-01 Electronic Governor Overview, Diagnosing, and Troubleshooting (Units with Governor Control Units 24 584 40-S or 24 584 56-S) There have been some reports regarding the function, adjustment, and troubleshooting of the electronic governor system. ȱȱȱȱȱȱȱȱęȱȱȱȱȱ¢. This document has been made to explain the system, aid in diagnosing and troubleshooting the system and its components.
Bulletins, Etc. ȱȱȱĞȱȱ¡ȱȱȱȱ the actuator reinstall as follows: 1. Disconnect linkage and remove the Digital Linear Actuator (DLA) from the control assembly. See Figure 1. 2. ȱȱĞȱ¢ȱȱȱ ǯȱ ȱ ȱśǯ 3. ȱȱȱȱȱȱ ȱȱǯ Governor Control Unit 4.
Bulletins, Etc. Harness/GCU Trouble Shooting and Diagnostic Procedures Ground and Power Tests The following two tests check for power and ground supply to the GCU. If either test fails the harness, electrical connections, or electrical system needs repair. 1. ȱȱ¢ȱȱȱěȱǯ 2. Remove the GCU and unplug the wiring harness. See Figures 6 and 7. NOTE: It is important to use the proper sized probes to preform the following test.
Bulletins, Etc. OHMsTests Blink Code Tests for the GCU Remove the GCU and unplug the wiring harness. See Figure 6 and 7. Speed control issues can also be diagnosis utilizing the onboard - “Blink Code” diagnostic lights equipped in the new style GCU. See Figure 13. The new GCUs do not store blink code trouble codes, however speed control problems that are experienced with a running engine can be quickly diagnosed using the light codes and the blink code chart. See Figure 14.
Bulletins, Etc. Kohler Engines - GCU (24 584 40-S or 24 584 56-S) Blink Codes LED Diagnostics Failure Condition Possible Causes Response Response Time Yellow LED Green LED Overspeed (Over 4500 RPM for 0.5 seconds sustained) External Noise on ignition input Ground to kill, close carb throttle plate 0.
Bulletins, Etc. Kohler Electronic Governor Troubleshooting Chart Turn off key switch Do Not Touch the Digital Linear Actuator (DLA) NOTE: The DLA is not a solenoid. It is a precision electronic motor. Do not exert force to the center clevis shaft! Visually inspect the DLA and Linkage. Figure 1 or 4 Fail if Pass if &RQ¿UP WKH IROORZLQJ 1. Clevis shaft and boot in place 2. Clip attached 3.
Bulletins, Etc. Kohler Electronic Governor Troubleshooting Chart (Continued) 12 Volt “Power Test” Locate the Speed Control input wire. The connection is either a single wire red w/yellow tracer, or a 6 pin connector body with a red wire w/yellow tracer. See Figures 16 or 17. Unplug and connect a jumper wire to the red wire with a yellow tracer on the engine wire harness. or Probe red w/yellow wire on 6 pin connector. Start the engine in the normal manner as described in the Owner’s Manual.
Bulletins, Etc. B+ Kill Tab (speed signal) 10 Power 8 12 Speed Signal 14 Device Ground Ignition Module DLA Driver Controls 13 1 2 6 7 2B 2A 1A 1B Application Supplied Speed Control Input DLA Operation Input Voltage: 0 Volts at Idle/12 Volts at High Speed Figure 17. Basic Electrical Diagram of System.
Bulletins, Etc. 2007-01 Kohler Engines Truck-Mounted Applications Grounding Instructions There have been some reports regarding poor cranking performance on Kohler Engine-powered truck-mounted air compressors. ȱȱȱȱȱȱȱȱȱȱȱ¢ȱȱȱȱĴ¢ȱȱȱȱ¢ȱȱ improperly grounded. Some installations are found to utilize the vȱĴ¢ǰȱ ȱȱȱȱĴ¢ȱȱȱȱ compressor.
Bulletins, Etc.
Technician’s Service Test Section 9 Technician’s Service Test This section contains two tests. The Gasoline test is 40 multiple-choice questions; the Diesel test is 10 multiple-choice questions. All questions have at least four possible answers, letters a, b, c, and d. Select the ONE best answer and mark your answer sheet by placing a dark “X” over the letter that LGHQWL¿HV \RXU VHOHFWLRQ Example: 25. The Kohler Engine plant is located in: a. Chicago, IL. b. Kohler, WI. c. Phoenix, AZ. d.
Technician’s Service Test Gasoline Test Questions 1. When should an EWR be started? a. When the Dealer is too busy to process a warranty claim. b. When the Representative feels the necessity to do a goodwill claim on behalf of his/her customer. c. When a Dealer or Representative cannot assess the cause of the failure in materials or workmanship. d. When the consumer is too irate to communicate.
Technician’s Service Test 11. What is covered in the Electronic Governor TechTips? a. Blink code information b. Mechanical checks c. Troubleshooting procedures d. All of the above .RKOHU 3/86 KDV DGGHG PDQ\ KHOSIXO IHDWXUHV WKLV \HDU WKH\ DUH a. Crankshaft illustrations and dimensions, carburetor repair kits when you enter a carburetor part number. b. New service and parts bulletins posted for one month on “”News Flash””, Fast Moving Parts c.
Technician’s Service Test 7KH ¿UVW VWHS LQ DQ\ VWDUWHU WHVWLQJ SURFHGXUH LV WR FKHFN EDWWHU\ YROWDJH :KDW LV WKH YROWDJH RI D IXOO\ FKDUJHG EDWWHU\" a. 13.8 to 14.7 VDC b. 12 volts c. 12.4 VDC or higher d. 15 Amps ,V WKHUH D FRQYHUVLRQ NLW IRU WKH DQDORJ 6$0 WR WKH '6$," D 1R EHFDXVH À\ZKHHO WLPLQJ DQG FLUFXLWU\ DUH GLIIHUHQW IRU HDFK V\VWHP b. Yes, because they have the same ignition module.
Technician’s Service Test :KDW IXHO ¿OWHU SDUW QXPEHU QXPEHUV FDQ EH XVHG RQ HQJLQHV ZLWK IXHO SXPSV" a. 25 050 22-S and 25 050 21-S b. 25 050 22-S and 52 050 02-S c. 25 050 22-S and 24 050 03-S d. 25 050 22-S and 12 050 01-S 7KH (:5 SURJUDP LV LQWHQGHG WR GHWHUPLQH ZKDW" a. If OEM equipment will work with defective parts. E 7KH GHJUHH DV WR ZKLFK WKH FRQVXPHU IHHOV FRQ¿GHQW ZLWK WKH SURGXFW c. The frequency of interaction between the factory and the dealers.
Technician’s Service Test Diesel Test Questions 7KH QHZ VW\OH NH\ IRU WKH /': DQG RU .': VHULHV HQJLQHV NH\ VZLWFK LV FXW RQ KRZ PDQ\ VLGHV" a. One b. Two c. None d. Three ,I UHSODFLQJ WKH ROG VW\OH FRRODQW WHPSHUDWXUH VZLWFK DQG WKHUPLVWRU VZLWFKHV ZLWK WKH QHZ VW\OH VLQJOH VZLWFK ZKDW LV WKH SDUW QXPEHU RI WKH SLJWDLO ZLULQJ DGDSWRU \RX ZLOO QHHG" a. ED2175-107-S b. ED5840-224-S c. ED2185-822-S d.
Technician’s Service Test $QVZHU 6KHHW IRU WKH .RKOHU 7HFKQLFLDQ¶V 6HUYLFH 3URJUDP 7HVW Name Company Name Warranty I.D. No. *DVROLQH 7HVW $QVZHU 6KHHW 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. a a a a a a a a a a a a a a a a a a a a b b b b b b b b b b b b b b b b b b b b c c c c c c c c c c c c c c c c c c c c d d d d d d d d d d d d d d d d d d d d 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40.
Technician’s Service Test 98
ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 LITHO IN U.S.A.
